“We weren’t using simulation at all until we started using the Tebis simulation system in 2013,” says Sal Mazza, Facilities Resource Manager, “It’s had a tremendous impact on our operations.”

Tebis simulation allows users to optimize machine operations by enabling them to identify and avoid possible collisions between component and tool geometry, check tool lengths before NC program calculation, and interactively define the optimum tilt direction. In addition, the system’s material removal simulation lets users realistically assess surface qualities.

These tools are particularly useful when Omega employs full 5-axis simultaneous milling. Before they calculate an NC program they can perform a detailed analysis of the tilt directions for the tool, also taking head geometry and machine kinematics into account. Collision avoidance calculations include the holder components defined in the Tebis tool library, and the Tebis simulator checks all machine components and limit switches.

“This not only lets us optimize machining, but it saves on programming time as well,” says Martin Chaput, Resource Utilization Manager.

“Using the Tebis simulator has resulted in huge savings,” he continues. “That’s because it allows us to maximize the utilization of our equipment and increase initial throughput.” He cites, for example, the fact that Omega can now run jobs on their smaller machines which had formerly been reserved for larger machines with more costly run-times in order to be sure to avoid reaching a machine limit. Now, with a precise knowledge of tool and fixture dimensions and how various components dynamically interact with a machining program, those fears are gone.

In keeping with its vision of data as a key indicator of the strategic performance enhancements that Omega is committed to, they instituted a resource (machine utilization) tracking system. Here, too, Tebis is playing a role, having interfaced its system to the resource dashboard, so that shopfloor personnel can access relevant CAD/CAM data.

“The system tracks machine efficiency and availability,” says Prebeg, “which translates into better machine utilization, and that is central to our plans for moving forward.

“Typically, companies usually run less than desirable capacities,” he continues. “After working with Tebis, as well as the other initiatives we’ve undertaken, we are running at over 90% utilization rates.” With the aid of the Tebis Multiple Setup module and new technology in the form of shuttles and material handling robots, Prebeg is confident that figure will largely improve.

This has been accompanied by a 10% reduction in total machining time required on any give job compared to the prior year, while overall productivity has increased by about 30% in the last two years.

Machine throughput has thus been drastically improved, and the other goals of the five year plan have been largely attained, or on track to be attained as well. For example, a significant portion of outsourced machining has been brought back in-house due to the company’s continued focus on throughput and the accuracy of the machine programs generated with Tebis software. As Chaput puts it, “Tebis cuts exactly, there are no wasted cuts.”

Engineering standardization has also proceeded, with all programming done in the same Tebis template style. Additionally, Omega is working with Tebis to optimize cutter paths and reduce air cutting, a more common occurrence than most tool shops realize or would care to admit. There has been a host of other improvements as well, but the key point was perhaps summarized by Tebis’ Benson when he observed, simply, “They’re pushing the envelope of what they can do.”

And they don’t plan on stopping. As Delko Prebeg observes, “We’re committed to our lean principles and continuous improvement -- that’s just who we are and what we do.”